MagicWave 1700 / 2200

TransTig 2200

TIG & MMA welding

What welders never dared dream of …

GENERAL REMARKS

Fronius works its magic again!

TIG welders can raise a heartfelt cheer! Specially for them,

Fronius has developed a series of machines that make

their every wish come true: MagicWave 1700/2200 for

DC and AC, and TransTig 2200 (for DC only).

These power sources are up-to-the-minute characters, in

every way, and eager to please: Ever-so discreet, with a

super-quiet yet highly stable arc. Extremely straightforward

to use – in fact, almost self-explanatory. Single-phase, so

they can be plugged into any wall power outlet. Light and

tough at the same time, and completely digitised – which

you won’t find on any other TIG machine.

What is more, every single one of these machines is a

member of a complete, totally co-ordinated welding

system, all of whose components perfectly complement

one another. All in all, the upshot is the sort of welding

results which up to now you could only dream of.

UTILISATION

Here, there, everywhere

One of the great things about the MagicWave and Trans-

Tig units is that they’re completely at home out in the

field. Weighing in at a mere 15 kg, these power sources

are among the lightest in the world, so you can take one

with you just about anywhere. Also, their sturdy design

makes them more than a match for the tough conditions

encountered in the field, and because they are single-

phase, they can simply be plugged into any ordinary 230 V

socket (wall outlet). And there aren’t too many places

where you won’t find one of those!

In terms of materials, these machines are very suitable

for aluminium and its alloys, but also for low and high-

alloy steels and non-ferrous metals, of course. Thanks to

their great versatility, the MagicWave 1700/2200 and

TransTig 2200 are used right across the entire spectrum

of industry – from the construction of chemical plant,

tanks and containers to mechanical and plant engineering

and pipeline construction, and taking in all site-erection,

structural metalworking, maintenance and repair firms.

Delivering just as perfect results when used for robot

welding as in manual welding.

ECONOMY

AAA-rated

This series of TIG machines is a dazzling example of just

how efficient modern welding systems can be. Their

efficiency begins with the high-grade componentry that

is used for all Fronius machines. Special mention should

also be made of their high degree of power efficiency,

extremely low open-circuit power, automatic cooling-unit

cut-out (which has a direct and measurable impact on

the current consumption), and of course the automatic

cap-shaping function, which reduces the working times

needed by the welder. All in all, these features result in

outstandingly long operational life, a small number of

wearing parts, and lower labour costs. And in a welding

system that is highly cost-effective in every possible

regard.

FACTS

Active Wave technology boosts profitability:

– Whole system is totally digitised: Power source, welding

torches, remote-control units, robot interfaces, PC tools.

– Digital signal processor (DSP) regulates and controls the

welding process.

– Available in both “Standard” and “Job” versions. “Job” offers

extra functions such as job-mode, and supports cold-wire

control and automated applications.

– Exceedingly high arc stability, even on aluminium base metals

from which the oxide has been completely removed; no

instability (verifiably so)!

– Special program for aluminium: Automatic shaping of the cap

on the pointed electrode tip, for perfect root fusion.

– TAC function for faster tacking of materials.

– Series feature: If welding is performed with two power

sources, both arcs are synchronised to permit simultaneous

welding on both sides.

UTILISATION

Materials

– Aluminium and its alloys

– Non-ferrous metals

– Low and high-alloy steels

Applications

– Manual welding

– Robot welding

Industrial sectors

– Construction of chemical plant, tanks and vessels, machinery

and plant

– Site-erection contractors

– Structural metalworking, maintenance and repair firms

– Pipeline construction

5 50 100 150 220 A

90

80

70

60

dbA

Masterpieces made easy

WELDING PROPERTIES

Perfection every step of the way

The Fronius welding systems have been thought out

right down to the last detail. For every possible applica-

tion, the goal was nothing less than perfection itself. The

result is a system that makes every single operating step

as easy and pleasant as possible. From ignition all the

way through to the end of the weld, from tack-welding to

shaping the electrode cap. But let’s take it all a step at

a time …

… starting with the ignition, which plays a key rôle in

TIG welding. On each of the three machines, ignition is

possible either with or without touchdown. In the non-

contact mode, the arc starts immediately with a high-

voltage impulse, ensuring perfect ignition right from the

first push of the button – even with extra-long hose-

packs. The touchdown ignition is especially valuable in

sensitive areas of application. And the important thing

here is to make sure that there are no tungsten inclu-

sions. The digital process control takes good care of

this, perfectly controlling the entire sequence.

Active Wave – for peace and quiet

From now on, TIG AC welding will be a much quieter

business – with a much quieter arc. No dream, this, but

hard fact. For which we have Active Wave to thank: the

integrated digital signal processor always computes –

in real time – the waveform that will permit the highest

possible arc stability with the lowest possible noise-

emissions levels. Measurement of these noise levels

clearly shows that with Active Wave, even when the

machine is delivering 220 A of power, the dbA value is

still below 80 dbA. If you’re not a welder yourself, and

want to know how important this development is, then

just ask one!

Noise volume from conventional inverters

Reduced noise volume from Active Wave

For sensitive areas of application: Touchdown ignition

New: Tack welding with TAC

Before you can weld, you have to tack. The usual way of

doing this – up until now, at least – is to make the two

weld-pools of the parts join up by making a slight move-

ment with the torch. With TAC, one spot is all it takes.

And on to the next one. And the one after that. And so

on. Because with TAC, the arc during tacking is not con-

tinuous, but pulsed. And this prompts the two weld-pools

to “jump together”, in next to no time, to make one single

weld-pool. This works fast, and is a lot easier. The TAC

function is also very useful when light-gauge sheets are

being welded without filler metal, as it helps the weld-

pools to merge more thoroughly.

Finish like you started

A perfect start needs a perfect finish to go with it. At the

end of the weld, there are two main things to watch out

for: The first of these is the gas post-flow, to make sure

that the electrode and the weld-pool do not oxidise. In

the past, the gas post-flow had to be set manually. On

the digital machines, the ideal post-flow time is computed

automatically. The second thing is the end crater. This

has to be filled, at a lower amperage. The new power

sources take care of this, too, with the crater-fill and

downslope function.

Simultaneous welding on both sides

When joining plates, you normally have to weld a root

pass first. This then has to be ground and back-welded -

a time-consuming procedure which you can speed up by

welding from both sides simultaneously. In “both-sides-

simultaneously” TIG-AC welding, both arcs have to be

synchronised. And to help you do this, the MagicWave

power sources have a “SyncMode” function which

harmonises both the arcs.

Special program for aluminium

Aluminium always needs special treatment. So Fronius

have made sure that it gets it. For example, in TIG AC

welding, aluminium is normally not welded with a pointed

electrode tip, but with a shaped cap at the tip of the

electrode. On fillet welds, this leads to inadequate root

fusion. The MagicWave machines use a pointed electrode

with a much smaller shaped cap, and perfect root fusion

as a result.

The cap is shaped automatically, by the way, which

means huge savings of time. All you need to do is clamp

the pointed electrode into the electrode holder, pre-select

the cap diameter (e.g. 1.6 mm), and the arc immediately

forms the shape and size of cap that you want. Another

interesting function enables you to make variable adjust-

ments to the AC waveform, giving the welder reliable

weld-pool control even at high amperages.

Right:

Cap diameter: 3.2 mm

Base metal: AIMg3

Sheet thickness: 5 mm

Welding amperage: 185 A

Welding voltage: 15.6 V

AC Balance: 0

Left:

Cap diameter: 1 mm

Base metal: AIMg3

Sheet thickness: 5 mm

Welding amperage: 185 A

Welding voltage: 15.6 V

AC Balance: -5

“Fully loaded” with comfort features for easier welding

HANDLING

Easy, easier, easiest

The machines come with an operating concept that is

simply exemplary. The control panel is just about entirely

self-explanatory, and correspondingly easy to use. Then

there is the facility for simplifying the panels still further

in practice, by activating only those functions and

controls that you are actually going to need. This makes

welding even more agreeable.

Remote-control à la carte

Remote control units are really practical. They come in

especially handy for welders, because they let you inter-

vene in the welding process and change parameters

directly at the scene of the action. No matter where your

welding machine happens to be. Special mention should

be made here of the JobMaster TIG welding torch, which

comes with integral remote control. This lets you call up

all your settings, any time and anywhere, regardless of

where the machine is standing. The JobMaster TIG

welding torch features a digital parameter display, job

recall and freely selectable parameters, meaning that you

decide for yourself which parameters you want to alter

during welding.

A few more words on the torch: Particularly advantage-

ously for TIG welding, this comes with a leather hose,

whose much greater flexibility means that the welder only

has a smaller proportion of the total weight of the torch

to carry with him while he works. The torch also has an

ergonomically shaped handle and a swivel-mounted

hosepack. Another great feature is the torch central

connector F++, with a separate water connector so that

there is absolutely no way that any coolant can get into

the gas channel and cause porosity in the weld metal.

Different types of job call for different types of welding

torch. Which is why there is a special one for robot appli-

cations, with an integrated cold-wire feeder unit. Or a

special cold-wire torch for manual welding, also with an

integrated wirefeed – used mainly for series applications

with good accessibility. By the way, the cold-wire control

system, complete with all parameters, is already integrated

in the power source.

Complete system, even including a TIG torch

Fronius is a system supplier. Each member of the system

is designed to “fit in” optimally with all the others, in

perfect harmony. It takes in everything from modularly

designed power sources (available for both gas and

water-cooled torches, incidentally), to remote-control

units, cooling units, trolleys and a wide range of different

robot interfaces, as well as complete welding-data

documentation and visualisation.

MagicWave 2200 “Job” control panelTransTig 2200 control panel

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SAFETY

Better safe than sorry

Anybody at all familiar with Fronius machines will know

that there’s absolutely no need to worry about their safety

features. Every power source comes with the CE mark

and with the [S] mark permitting welding in confined

spaces in conditions of enhanced electrical hazard, also

when AC welding, of course. Also, all of the power

sources amply fulfil the requirements of IEC “degree of

protection IP 23”, meaning that they are safely protected

from dirt and water, for use in the field. The integral fan is

thermostat-controlled and so only runs when it is needed.

This reduces dirt collection and prolongs the service life

of the power source. At Fronius, though, safety starts

even sooner: in the development stage. The MagicWave

and TransTig machines were designed from the ground

up to be so robust and compact that they can take just

about anything in their stride.

CHECKLIST

Digital weld-process control

Microprocessor control

Energy-saving inverter technology

Generator-compatible

Thermostat-controlled fan / overtemperature protection

Earth leakage monitoring

Continuous welding-current adjustment from torch

Remote-controllable

Switchover facility between touchdown and HF ignition

Automatic gas post-flow (dep. on welding current)

Gas-test function

Automatic cooling-unit cut-out

Anti-stick function

Freely selectable parameters on the welding torch1

Job mode1

Automatic cap-shaping function

Polarity reversal

RPI ignition

Rate-of-flow watchdog for torch cooling system

External current-flow signal

Robot interface, analogue/digital1

Cold-wire control1

Operating modes2-step mode / 4-step mode

TAC (programmed tack-welding)

AC / DC

Special 4-step mode1

TIG-Puls1

Spot welding1

Digital indication ofRun-status

Operating mode

Welding voltage, welding amperage (actual value)

“Hold” function

Overtemperature

Service code

Mains voltage monitoring

Job number1

Adjustable parametersWelding power (continuously adjustable)

Electrode diameters

Gas pre-flow time / gas post-flow time

Crater-fill current / start-arc

UpSlope / DownSlope

Hot-Start / arc-force dynamic

AC balance / AC frequency / AC waveform

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Pictures from left to right:

For cold-wire applications: TTW 4000 KD welding torch with integrated remote-control, display and wirefeed

The KD 4000D-11 feeder unit ensures perfect wirefeeding in cold-wire applications

TR 2200 F pedal remote-control unit: For precision control of the welding current,all the time

RCU 2000 remote control unit: For completely remote-controlling the power source

JobMaster TIG torch with integrated remote control and display

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Mains voltage, 50-60 Hz 230 V 230 V 230 V

Mains voltage tolerance -20 / +15 % -20 / +15 % -20 / +15 %

Mains fuse protection (slow-blow) 16 A 16 A 16 A

Primary continuous current (100 % d.c.) 3.3 kVA 3.7 kVA 3.0 kVA

Cos phi 1 0.99 0.99 0.99

Welding-current range (continuous) TIG 3 - 170 A 3 - 220 A 3 - 220 A

Electrode 10 - 140 A 10 - 180 A 10 - 180 A

Welding current at 10 min/25° C 40 % d.c. 170 A 40 % d.c. 220 A 50 % d.c. 220 A

60 % d.c. 140 A 60 % d.c. 180 A 60 % d.c. 200 A

100 % d.c. 110 A 100 % d.c. 150 A 100 % d.c. 170 A

10 min/40° C 35 % d.c. 170 A 35 % d.c. 220 A 40 % d.c. 220 A

60 % d.c. 130 A 60 % d.c. 170 A 60 % d.c. 180 A

100 % d.c. 100 A 100 % d.c. 150 A 100 % d.c. 150 A

Open-circuit voltage 88 V 88 V 84 V

Standardised operating voltage TIG 10.1 -16,8 V 10.1 - 18.8 V 10.1 - 18.8 V

Electrode 20.4 - 25.6 V 20.4 - 27.2 V 20.4 - 27.2 V

Ignition voltage (Up)* 10.0 kV 9.5 kV 9.5 kV

Degree of protection IP 23 IP 23 IP 23

Type of cooling AF AF AF

Insulation class B B B

Dimensions L x W x H mm 485 x 180 x 344 485 x 180 x 390 485 x 180 x 390

Inch 19.09 x 7.09 x 13.54 19.09 x 7.09 x 15.35 19.09 x 7.09 x 15.35

Weight 15 kg / 33.1 lb 17.4 kg / 38.4 lb 16.8 kg / 37 lb

*The arc ignition feature is suitable for manual operation.

Mains voltage, 50 - 60 Hz 230 V

Mains voltage tolerance -20 / +15 %

Cooling capacity Q = 1 l/min. +25 °C 660 W

+40 °C 450 W

Delivery rate 3.0 l/min

Delivery head 30 m

Max. pump pressure 4.2 bar

Coolant capacity 1.5 l

Degree of protection IP 23

Dimensions L x W x H mm 540 x 180 x 180

Inch 21.26 x 7.09 x 7.09

Weight (without coolant) 6.6 kg / 14.5 lb

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TECHNICAL DATA

MagicWave 1700 / Job MagicWave 2200 / Job TransTig 2200 / JobPower source

Welding current AC 180 A 220 A 250 A

DC 220 A 260 A 300 A

Duty cycle 35 % 35 % 60 %

Electrode diameters 1.0 - 4.0 mm 1.6 - 6.4 mm 1.0 - 3.2 mm

Weight 0.96 kg / 2.1 lb 1.2 kg / 2.6 lb 0.75 kg / 1.7 lb

TTG 2200 A TTG 2600 A TTW 3000 AWelding torch

Cooling unit FK 2200

40,0

006,

2231

(1/0

5)

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